Tubular form biomedical device batteries with electroless sealing

Abstract

Designs, strategies and methods for forming tube shaped batteries are described. In some examples, hermetic seals may be used to seal battery chemistry within the tube-shaped batteries. This may improve biocompatibility of energization elements. In some examples, the tube form biocompatible energization elements may be used in a biomedical device. In some further examples, the tube form biocompatible energization elements may be used in a contact lens.

What is claimed is: 
     
         1 . A biomedical device comprising:
 an electroactive component;   a battery comprising:an anode current collector;
 a cathode current collector; 
 an anode; 
 a cathode; 
 a tube encapsulating the anode and cathode with a first penetration for the anode current collector, a second penetration for the cathode current collector, a first seal between the tube and the anode current collector and a second seal between the tube and the cathode current collector; 
   a plated metallic exterior coating, wherein the plated metallic exterior coating comprises a portion that is plated with electroless plating, and wherein the thickness of the plated metallic exterior coating is thick enough to act as a barrier to ingress and egress of moisture from the battery; and   a first biocompatible encapsulating layer, wherein the first biocompatible encapsulating layer encapsulates at least the electroactive component and the battery.   
     
     
         2 . A battery comprising:
 an anode current collector, wherein the anode current collector is a first metallic tube closed on a first end;   an anode, wherein the anode chemistry is contained within the first metallic tube;   a cathode current collector, wherein the cathode current collector is a second metallic tube closed on a second end;   a cathode, wherein the cathode chemistry is contained within the second metallic tube;   a ceramic tube with a first sealing surface that sealably interfaces with the first metallic tube and a second sealing surface that sealably interfaces with the second metallic tube;   a sealing material located in a gap between the first sealing surface and first metallic tube; and   a plated metallic exterior coating, wherein the plated metallic exterior coating comprises a portion that is plated with electroless plating, and wherein the thickness of the plated metallic exterior coating is thick enough to act as a barrier to ingress and egress of moisture from the battery.   
     
     
         3 . The battery of  claim 2  wherein the sealing material located in the gap between the first sealing surface and the first metallic tube comprises an epoxy adhesive. 
     
     
         4 . The battery of  claim 2  wherein the sealing material located in the gap between the first sealing surface and the first metallic tube comprises a first layer comprising molybdenum and manganese particles in a mixture with ceramic powders which is then plated with a metallic film. 
     
     
         5 . The battery of  claim 4  wherein the metallic film comprises nickel. 
     
     
         6 . The battery of  claim 2  wherein the sealing material located in the gap between the first sealing surface and the first metallic tube comprises a first layer of a PVD deposited metallic film. 
     
     
         7 . The battery of  claim 6  wherein the metallic film comprises titanium. 
     
     
         8 . The battery of  claim 7  wherein a noble metallic film is additionally deposited upon the PVD deposited metallic film. 
     
     
         9 . The battery of  claim 2  wherein the sealing material located in the gap between the first sealing surface and the first metallic tube comprises a plurality of thin layers of metallic films, wherein a first thin layer of metallic film is deposited upon a second layer of metallic film, wherein the first thin layer of metallic film is chemically reactive with the second layer of metallic film releasing energy to rapidly heat the layers, and wherein the chemical reaction is activated by an energetic pulse of energy. 
     
     
         10 . The battery of  claim 9  wherein the energetic pulse comprises photons. 
     
     
         11 . The battery of  claim 9  wherein the energetic pulse comprises electrons. 
     
     
         12 . The battery of  claim 9  wherein the energetic pulse comprises thermal energy. 
     
     
         13 . The battery of  claim 2  wherein the sealing material located in the gap between the first sealing surface and the first metallic tube comprises a conventional solder alloy base with an addition of titanium, wherein the titanium reacts with surface materials of the ceramic upon exposure to ultrasonic energy. 
     
     
         14 . A battery comprising:
 an anode current collector, wherein the anode current collector is a first metallic tube closed on a first end;   an anode, wherein the anode chemistry is contained within the first metallic tube;   a cathode current collector, wherein the cathode current collector is a second metallic tube closed on a second end;   a cathode, wherein the cathode chemistry is contained within the second metallic tube;   a glass tube with a first sealing surface that sealably interfaces with the first metallic tube and a second sealing surface that sealably interfaces with the second metallic tube;   a sealing material located in a gap between the first sealing surface and first metallic tube; and   a plated metallic exterior coating, wherein the plated metallic exterior coating comprises a portion that is plated with electroless plating, and wherein the thickness of the plated metallic exterior coating is thick enough to act as a barrier to ingress and egress of moisture from the battery.   
     
     
         15 . The battery of  claim 14  wherein the sealing material located in the gap between the first sealing surface and the first metallic tube comprises an epoxy adhesive. 
     
     
         16 . The battery of  claim 14  wherein the sealing material located in the gap between the first sealing surface and the first metallic tube comprises a first layer comprising molybdenum and manganese particles in a mixture with ceramic powders which is then plated with a metallic film. 
     
     
         17 . The battery of  claim 16  wherein the metallic film comprises nickel. 
     
     
         18 . The battery of  claim 14  wherein the sealing material located in the gap between the first sealing surface and the first metallic tube comprises a first layer of a PVD deposited metallic film. 
     
     
         19 . The battery of  claim 18  wherein the metallic film comprises titanium. 
     
     
         20 . The battery of  claim 19  wherein a noble metallic film is additionally deposited upon the PVD deposited metallic film. 
     
     
         21 . The battery of  claim 14  wherein the sealing material located in the gap between the first sealing surface and the first metallic tube comprises a plurality of thin layers of metallic films, wherein a first thin layer of metallic film is deposited upon a second layer of metallic film, wherein the first thin layer of metallic film is chemically reactive with the second layer of metallic film releasing energy to rapidly heat the layers, and wherein the chemical reaction is activated by an energetic pulse of energy. 
     
     
         22 . The battery of  claim 21  wherein the energetic pulse comprises photons. 
     
     
         23 . The battery of  claim 21  wherein the energetic pulse comprises electrons. 
     
     
         24 . The battery of  claim 21  wherein the energetic pulse comprises thermal energy. 
     
     
         25 . The battery of  claim 14  wherein the sealing material located in the gap between the first sealing surface and the first metallic tube comprises a conventional solder alloy base with an addition of titanium, wherein the titanium reacts with surface materials of the glass upon exposure to ultrasonic energy. 
     
     
         26 . A battery comprising:
 an anode current collector, wherein the anode current collector is a first metallic tube closed on a first end;   an anode, wherein the anode chemistry is contained within the first metallic tube;   a cathode current collector, wherein the cathode current collector is wire;   a ceramic end cap with a first sealing surface that sealably interfaces with the first metallic tube and a second sealing surface that sealably interfaces with the cathode current collector;   a cathode, wherein the cathode chemistry is deposited upon the cathode current collector;   a sealing material located in a gap between the first sealing surface and first metallic tube; and   a plated metallic exterior coating, wherein the plated metallic exterior coating comprises a portion that is plated with electroless plating, and wherein the thickness of the plated metallic exterior coating is thick enough to act as a barrier to ingress and egress of moisture from the battery.   
     
     
         27 . A battery comprising:
 an anode current collector, wherein the anode current collector is a first semiconductor tube closed on a first end and doped on the first end;   an anode, wherein the anode chemistry is contained within the first semiconductor tube;   a cathode current collector, wherein the cathode current collector is a second semiconductor tube closed on a second end and doped on the second end;   a cathode, wherein the cathode chemistry is deposited upon the cathode current collector;   a sealing material located in a gap between the first semiconductor tube and the second semiconductor tube; and   a plated metallic exterior coating, wherein the plated metallic exterior coating comprises a portion that is plated with electroless plating, and wherein the thickness of the plated metallic exterior coating is thick enough to act as a barrier to ingress and egress of moisture from the battery.   
     
     
         28 . The battery of  claim 27  wherein the sealing material located in the gap between the first semiconductor tube and the second semiconductor tube comprises an epoxy adhesive. 
     
     
         29 . The battery of  claim 27  wherein the sealing material located in the gap between the first semiconductor tube and the second semiconductor tube comprises a first layer comprising molybdenum and manganese particles in a mixture with ceramic powders which is then plated with a metallic film. 
     
     
         30 . The battery of  claim 29  wherein the metallic film comprises nickel. 
     
     
         31 . The battery of  claim 27  wherein the sealing material located in the gap between the first semiconductor tube and the second semiconductor tube comprises a first layer of a PVD deposited metallic film. 
     
     
         32 . The battery of  claim 31  wherein the metallic film comprises titanium. 
     
     
         33 . The battery of  claim 32  wherein a noble metallic film is additionally deposited upon the PVD deposited metallic film. 
     
     
         34 . The battery of  claim 27  wherein the sealing material located in the gap between the first semiconductor tube and the second semiconductor tube comprises a plurality of thin layers of metallic films, wherein a first thin layer of metallic film is deposited upon a second layer of metallic film, wherein the first thin layer of metallic film is chemically reactive with the second layer of metallic film releasing energy to rapidly heat the layers, and wherein the chemical reaction is activated by an energetic pulse of energy. 
     
     
         35 . The battery of  claim 34  wherein the energetic pulse comprises photons. 
     
     
         36 . The battery of  claim 34  wherein the energetic pulse comprises electrons. 
     
     
         37 . The battery of  claim 34  wherein the energetic pulse comprises thermal energy. 
     
     
         38 . The battery of  claim 27  wherein the sealing material located in the gap between the first semiconductor tube and the second semiconductor tube comprises a conventional solder alloy base with an addition of titanium, wherein the titanium reacts with surface materials of the first semiconductor tube and the second semiconductor tube upon exposure to ultrasonic energy. 
     
     
         39 . A battery comprising:
 an anode current collector, wherein the anode current collector is a first metallic tube closed on a first end;   an anode, wherein the anode chemistry is contained within the first metallic tube;   a cathode current collector, wherein the cathode current collector is a second metallic tube closed on a second end;   a cathode, wherein the cathode chemistry is contained within the second metallic tube;   a plastic tube with a first sealing surface that sealably interfaces with the first metallic tube and a second sealing surface that sealably interfaces with the second metallic tube;   a sealing material located in a gap between the first sealing surface and first metallic tube; and   a plated metallic exterior coating, wherein the plated metallic exterior coating comprises a portion that is plated with electroless plating, and wherein the thickness of the plated metallic exterior coating is thick enough to act as a barrier to ingress and egress of moisture from the plastic tube.   
     
     
         40 . The battery of  claim 39  wherein the sealing material located in the gap between the first sealing surface and the first metallic tube comprises an epoxy adhesive. 
     
     
         41 . A method of manufacturing a battery comprising:
 obtaining a cathode collector tube;   filling the cathode collector tube with cathode chemicals;   obtaining an anode collector tube;   filling the anode collector tube with anode chemicals;   obtaining a tube form ceramic insulator piece;   forming a first and second sealing surface on each end of the tube form ceramic insulator piece;   evaporating a metal film upon the first and second sealing surface;   coating the end of the cathode collector tube with a piece of Nanofoil;   coating the metal film upon the first and second sealing surface with a solder paste;   positioning the cathode collector tube over the first sealing surface;   activating the Nanofoil to cause a rapid temperature increase at an interface between the cathode collector tube and the first sealing surface and melting the solder paste; and   plating a metallic exterior coating, wherein at least a first portion of the metallic exterior coating comprises a portion that is plated with electroless plating, and wherein the thickness of the plated metallic exterior coating is thick enough to act as a barrier to ingress and egress of moisture from the battery.